Abstract: Methods, systems, and apparatus, including medium-encoded computer program products, for injection molding warp prediction include: obtaining a mold model and measured shrinkage data for at least one material, predicting an amount of warpage for a part manufactured using the mold by computational simulation of an injection molding process, where the computational simulation uses an internal residual stress model for the part that uses calibrated values for both a coefficient of thermal expansion and an elastic modulus and/or a Poisson's ratio of the at least one material, in at least one direction, for at least thermal stress due to cooling and pressure compensation during and/or after a packing phase of the injection molding process, in accordance with the measured shrinkage data for the at least one material, and providing the amount of warpage predicted for the part manufactured using the mold.

Abstract: A digital 3D model of a component to be analyzed is obtained. The component includes regularly patterned holes. A first portion of the model is identified. The first portion includes the regularly patterned holes. A second portion of the model is identified. The second portion includes parts of the model lacking the regularly patterned holes. A flow factor of the first portion is determined. The flow factor indicates flow characteristics of fluid flowing through the first portion with the regularly patterned holes. A numerical fluid simulation is performed using a mesh representative of the component geometry. Performing the numerical fluid simulation includes modifying a flow property of the fluid simulation in the first portion based at least in part on the flow factor.

Abstract: Methods, systems, and apparatus, including medium-encoded computer program products, for injection molding warp prediction include: obtaining a mold model and measured shrinkage data for at least one material, predicting an amount of warpage for a part manufactured using the mold by computational simulation of an injection molding process, where the computational simulation uses an internal residual stress model for the part that uses calibrated values for both a coefficient of thermal expansion and an elastic modulus and/or a Poisson's ratio of the at least one material, in at least one direction, for at least thermal stress due to cooling and pressure compensation during and/or after a packing phase of the injection molding process, in accordance with the measured shrinkage data for the at least one material, and providing the amount of warpage predicted for the part manufactured using the mold.

Abstract: The invention relates to a method and apparatus for analyzing fluid flow while considering heat transfer effects and, in particular, a phase change from a molten state to a solid state. In particular, the method and apparatus may be applied to the analysis of an injection molding process for producing a molded polymer component from a thermoplastic or a thermosetting polymer. In one embodiment, the method may be used to determine pressure required to fill a mold cavity and pressure gradients introduced during filling and packing of the cavity of an injection mold. The results of these analyses may be used to determine the number and location of gates, to determine the best material for the component, and to optimize the process conditions used in the molding process.